Nonwoven fabric laminate, absorbent article having nonwoven fabric laminate, and process for producing nonwoven fabric laminate

ABSTRACT

An absorbent article comprising an exterior sheet formed of a nonwoven fabric laminate (1) in which a first nonwoven fabric layer (2), a second nonwoven fabric layer (3) and a third nonwoven fabric layer (4) are laminated from the outer side, wherein the first nonwoven fabric layer (2), the second nonwoven fabric layer (3) and the third nonwoven fabric layer (4) are joined to each other at a first joining part (6) by heat-embossing, and the second nonwoven fabric layer (3) and the third nonwoven fabric layer (4) are further joined to each other at a second joining part (7) by heat-embossing.

TECHNICAL FIELD

The present invention relates to a nonwoven fabric laminate, aproduction method therefore and an absorbent article having the nonwovenfabric laminate such as a disposable diaper, an incontinence pad(including a light incontinence pad) and a sanitary napkin.

BACKGROUND ART

A nonwoven fabric is widely used in life materials and industrialmaterials, and various kinds of nonwoven fabrics are known. In absorbentarticles such as disposable diapers, nonwoven fabrics are widely used asa constituent member thereof, and optimal nonwoven fabrics according tothe usage are variously examined. For example, a sheet member disposedon an outer side of an absorbent article (an exterior sheet) is a memberwhich a user often touches by hand and strongly contacts to a wearer'sunderwear or clothing, and hence, it is preferred that it has sufficientstrength and good hand feeling. Even in other applications, nonwovenfabrics have many opportunities to be touched by hand, and it ispreferably provided with such characteristics. As a method forincreasing the strength of nonwoven fabrics, for example, PatentLiterature 1 discloses a disposable diaper provided with a sheet membermade of a nonwoven fabric of which an outer surface is embossed, anddescribes that the emboss of the nonwoven fabric increases interfiberstrength and suppresses fuzzing.

CITATION LIST Patent Literature Patent Literature 1

Japanese Unexamined Laid-open Patent Application Publication No.2007-29612

SUMMARY OF INVENTION Technical Problem

The present invention has been achieved in view of the abovecircumstances, and the object of the present invention is to provide anonwoven fabric laminate that is excellent in conflicting bothproperties of strength and hand feeling, a production process therefor,and further, an absorbent article comprising an exterior sheet providedon an outer side thereof, that is excellent in both properties ofstrength and hand feeling.

Solution to Problem

A nonwoven fabric laminate of the present invention which solves theabove problems is the nonwoven fabric laminate in which a first nonwovenfabric layer, a second nonwoven fabric layer and a third nonwoven fabriclayer are laminated in this order, wherein the first nonwoven fabriclayer, the second nonwoven fabric layer and the third nonwoven fabriclayer are joined to each other at a first joining part byheat-embossing, and the second nonwoven fabric layer and the thirdnonwoven fabric layer are further joined to each other at a secondjoining part by heat-embossing. In the nonwoven fabric laminate of thepresent invention, since the second nonwoven fabric layer and the thirdnonwoven fabric layer are joined to each other at both the first joiningpart and the second joining part by heat-embossing, strength of thenonwoven fabric laminate can be increased. And, since the first nonwovenfabric layer is joined to the second nonwoven fabric layer only at thefirst joining part, joining parts formed by heat-embossing are decreasedand hand feeling of the first nonwoven fabric layer side of the nonwovenfabric laminate can be made good.

It is preferred that an area of the one first joining part is largerthan that of the one second joining part. When the first joining part isprovided in this manner, the first nonwoven fabric layer, the secondnonwoven fabric layer and the third nonwoven fabric layer are firmlyjoined to each other at the first joining part, thereby increasingintegrity of the nonwoven fabric laminate.

It is preferred that each of the first nonwoven fabric layer, the secondnonwoven fabric layer and the third nonwoven fabric layer is made of aspunbonded nonwoven fabric or an air-through nonwoven fabric. When eachof the first nonwoven fabric layer, the second nonwoven fabric layer andthe third nonwoven fabric layer is made of a spunbonded nonwoven fabricor an air-through nonwoven fabric, breathability of the nonwoven fabriclaminate is increased and internal humidity is easily decreased in thecase where the nonwoven fabric laminate is applied to variousapplications. In this case, the first joining part preferably has ashape that is shorter in an orientation direction of fibers constitutingthe nonwoven fabric than in an orthogonal direction thereof. When thefirst joining part is provided in this manner, breaking strength of thespunbonded nonwoven fabric or the air-through nonwoven fabric withrespect to a direction orthogonal to the fiber orientation direction canbe increased and integrity of the first nonwoven fabric layer, thesecond nonwoven fabric layer and the third nonwoven fabric layer iseasily maintained.

The first joining part and the second joining part may have a differentshape from each other. When the first joining part and the secondjoining part are formed in this manner, it becomes possible to give adesired physical property to the nonwoven fabric laminate in accordancewith an actual usage. For example, it is possible to determine the shapeof the first joining part from the viewpoint of ensuring the integrityof the nonwoven fabric laminate and determine the shape of the secondjoining part from the viewpoint of increasing the strength of thenonwoven fabric laminate.

The present invention also provides a process for producing a nonwovenfabric laminate. A process for producing a nonwoven fabric laminate ofthe present invention comprises the steps in the sequence set forth:forming a third nonwoven fabric layer; forming a second nonwoven fabriclayer on the third nonwoven fabric layer; heat-embossing the secondnonwoven fabric layer and the third nonwoven fabric layer to join toeach other at a second joining part; forming a first nonwoven fabriclayer on the second nonwoven fabric layer; and heat-embossing the firstnonwoven fabric layer, the second nonwoven fabric layer and the thirdnonwoven fabric layer to join to each other at a first joining part.According to the process for producing a nonwoven fabric laminate of thepresent invention, the nonwoven fabric laminate of the present inventioncan be easily manufactured.

The nonwoven fabric laminate of the present invention is preferablyapplied to an exterior sheet located on an outer side of an absorbentarticle, whereby hand feeling of the exterior sheet can be improvedwhile strength thereof is increased. That is, an absorbent article ofthe present invention comprises an exterior sheet formed of a pluralityof nonwoven fabric layers, wherein the exterior sheet is located on anouter side of the absorbent article and has a first nonwoven fabriclayer, a second nonwoven fabric layer and a third nonwoven fabric layerfrom the outer side of the absorbent article, the first nonwoven fabriclayer, the second nonwoven fabric layer and the third nonwoven fabriclayer are joined to each other at a first joining part byheat-embossing, and the second nonwoven fabric layer and the thirdnonwoven fabric layer are further joined to each other at a secondjoining part by heat-embossing. In the absorbent article of the presentinvention, since the second nonwoven fabric layer and the third nonwovenfabric layer of the exterior sheet are joined to each other at both thefirst joining part and the second joining part by heat-embossing,strength of the exterior sheet can be increased. And, since the firstnonwoven fabric layer is provided on the outer side of the secondnonwoven fabric layer and is joined to the second nonwoven fabric layerat the first joining part, joining parts formed by heat-embossing aredecreased and hand feeling of the exterior sheet can be made good.

In the case that an elastic member is disposed to a skin-facing side ofthe exterior sheet, it is preferred that the first joining part has ashape that is shorter in an extending direction of the elastic memberthan in an orthogonal direction thereof. When the first joining part isprovided in this manner, many wrinkles extending in a directionorthogonal to the extending direction of the elastic member are easilyformed in the exterior sheet, and the elastic member can be made hardlyto be seen from the outside of the exterior sheet. From the sameviewpoint, it is also preferable that a plurality of the first joiningparts are aligned in an extending direction of the elastic member and anorthogonal direction thereof, and a distance between the first joiningparts in the extending direction is wider than that in the orthogonaldirection.

In the case that the absorbent article is a pants-type disposable diaperand an elastic member extending in a width direction of the diaper isdisposed at a body circumference part of the diaper between the exteriorsheet and an inner sheet provided on a skin-facing side of the exteriorsheet, it is preferred that the first joining part has a shape that islonger in a longitudinal direction of the diaper than in the widthdirection of the diaper. When the first joining part is provided in thismanner, many wrinkles extending in the longitudinal direction are formedin the exterior sheet, and the elastic member can be made hardly to beseen from the outside of the exterior sheet. In this case, from the sameviewpoint, it is also preferable that a plurality of the first joiningparts are aligned in the longitudinal direction of the diaper and thewidth direction of the diaper, and a distance between the first joiningparts in the width direction of the diaper is wider than that in thelongitudinal direction of the diaper.

Advantageous Effects of Invention

In the nonwoven fabric laminate of the present invention, the firstnonwoven fabric layer, the second nonwoven fabric layer and the thirdnonwoven fabric layer are joined to each other at the first joining partby heat-embossing, and the second nonwoven fabric layer and the thirdnonwoven fabric layer are further joined to each other at the secondjoining part by heat-embossing. Therefore, strength of the nonwovenfabric laminate is ensured by the heat-emboss of the second nonwovenfabric layer and the third nonwoven fabric layer at the first and secondjoining part, and hand feeling of the first nonwoven fabric layer sideof the nonwoven fabric laminate can be made good by heat-embossing thefirst nonwoven fabric layer only at the first joining part. Further,according to the absorbent article of the present invention in which thenonwoven fabric laminate of the present invention is used for theexterior sheet, strength of the exterior sheet is ensured and handfeeling thereof is made good.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 represents an example of a nonwoven fabric laminate and shows aperspective view of the nonwoven fabric laminate.

FIG. 2 represents another example of a nonwoven fabric laminate andshows a perspective view of the nonwoven fabric laminate.

FIG. 3 shows a schematic view of a process for producing the nonwovenfabric laminate shown in FIG. 1.

FIG. 4 shows a plan view of a skin-facing side of an incontinence pad asan absorbent article.

FIG. 5 shows a cross-sectional view along a line V-V of the incontinencepad shown in FIG. 4.

FIG. 6 shows a perspective view of a pants-type disposable diaper as anabsorbent article.

FIG. 7 shows a plan view of the pants-type disposable diaper shown inFIG. 6 in a developed state where a front part and a rear part aredisjoined.

FIG. 8 shows a cross-sectional view along a line VIII-VIII of thepants-type disposable diaper shown in FIG. 7.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Nonwoven Fabric Laminate

A nonwoven fabric laminate of the present invention comprises aplurality of nonwoven fabric layers, wherein the nonwoven fabric layerswhich are laminated adjacently are joined to each other byheat-embossing. The nonwoven fabric laminate of the present inventioncan be made to have good hand feeling while ensuring strength, byappropriately setting a pattern of the heat-emboss for boding thenonwoven fabric layers to each other.

The nonwoven fabric laminate comprises a first nonwoven fabric layer, asecond nonwoven fabric layer and a third nonwoven fabric layer. Thefirst nonwoven fabric layer, the second nonwoven fabric layer and thethird nonwoven fabric layer are laminated in this order, and the firstnonwoven fabric layer preferably becomes a surface which a user mainlytouches by hand. That is, it is preferred that the first nonwoven fabriclayer faces outward.

The nonwoven fabric laminate of the present invention can be applied toconventionally-known applications of nonwoven fabrics, that include, forexample, absorbent articles such as a disposable diaper and anincontinence pad; covers such as a pillow cover, a shoe cover and a suitcover; bags such as a storage bag; protective clothing such as aprotective suit and a surgical gown; and sheets such as a drape, anagricultural sheet, a wet tissue and a wet towel. In the case ofapplying to absorbent articles, covers, bags and protective clothing, itis preferred that the first nonwoven fabric layer is located on an outersurface thereof, whereby hand feeling of the nonwoven fabric product canbe made good. In the case of applying to sheets, the first nonwovenfabric layer is preferably located on an outer surface thereof duringuse, or the nonwoven fabric laminate may be folded so that the firstnonwoven fabric layer is located outside.

In the nonwoven fabric laminate, the first nonwoven fabric layer, thesecond nonwoven fabric layer and the third nonwoven fabric layer arejoined to each other at a first joining part by heat-embossing, and thesecond nonwoven fabric layer and the third nonwoven fabric layer arefurther joined to each other at a second joining part by heat-embossing.That is, the first nonwoven fabric layer, the second nonwoven fabriclayer and the third nonwoven fabric layer are heat-embossed together atthe first joining part to be joined to each other. The second joiningpart is formed by heat-embossing the second nonwoven fabric layer andthe third nonwoven fabric layer, and the first nonwoven fabric layer andthe second nonwoven fabric layer are not joined by embossing at thesecond joining part.

Since the nonwoven fabric laminate is configured in the above manner,both strength and hand feeling can be enhanced. Strength of a nonwovenfabric is generally increased by heat-embossing, and for example, thenonwoven fabric can be made to be hardly broken even when it is pulled;however, the nonwoven fabric tends to be hardened at the heat-embossedpart, that deteriorates hand feeling of the nonwoven fabric.Nevertheless, in the present invention, among the nonwoven fabric layersconstituting the nonwoven fabric laminate, the second nonwoven fabriclayer and the third nonwoven fabric layer are joined at both the firstjoining part and the second joining part by heat-embossing, wherebystrength of the nonwoven fabric laminate can be increased. And, thefirst nonwoven fabric layer is joined to the second nonwoven fabriclayer only at the first joining part, whereby joining parts formed byheat-embossing are decreased and hand feeling of the first nonwovenfabric layer side of the nonwoven fabric laminate can be made good. Inaddition, since the first nonwoven fabric layer, the second nonwovenfabric layer and the third nonwoven fabric layer are heat-embossedtogether at the first joining part, integrity of the nonwoven fabriclayers constituting the nonwoven fabric laminate can be ensured.Further, since the nonwoven fabric laminate of the present invention isformed such that the joining pattern of the first nonwoven fabric layerwith the second nonwoven fabric layer is different from that of thesecond nonwoven fabric layer with the third nonwoven fabric layer,interlayer distances between the respective nonwoven fabric layers arevariously changed, that makes degree of transmission or diffusion oflight through the nonwoven fabric laminate uneven properly, whereby avisual shielding property through the nonwoven fabric laminate can beincreased.

In the present invention, the nonwoven fabric laminate are formed bylaminating the first nonwoven fabric layer, the second nonwoven fabriclayer and the third nonwoven fabric layer and is handled as a singlesheet member. Therefore, in the nonwoven fabric laminate, it ispreferred that the second nonwoven fabric layer is provided between thefirst nonwoven fabric layer and the third nonwoven fabric layer, thesecond nonwoven fabric layer is provided adjacent to the first nonwovenfabric layer and the third nonwoven fabric layer, and any other memberis not provided both between the first nonwoven fabric layer and thesecond nonwoven fabric layer and between the second nonwoven fabriclayer and the third nonwoven fabric layer. In the case that a fourthnonwoven fabric layer is provided as described below, it is preferredthat the fourth nonwoven fabric layer is provided adjacent to the thirdnonwoven fabric layer and any other member is not also provided betweenthe third nonwoven fabric layer and the fourth nonwoven fabric layer.

In the nonwoven fabric laminate, a plurality of the nonwoven fabriclayers are laminated and integrated by heat-embossing. In the nonwovenfabric laminate, at the first joining part and the second joining partthat are heat-embossed, certain embossed patterns are formed by pressingwhile the adjacent nonwoven fabric layers are joined to each other bythermal fusion bonding. Heat-embossing may be conducted by bringing aheated heat-transfer material contact with the nonwoven fabric layer tomelt a part of the nonwoven fabric layer or by bringing a ultrasonictransducer contact with the nonwoven fabric layer to melt a part of thenonwoven fabric layer with ultrasonic vibration, in the state where thenonwoven fabric layers are laminated.

The nonwoven fabric laminate may further comprise another layer inaddition to the first nonwoven fabric layer, the second nonwoven fabriclayer and the third nonwoven fabric layer. The another layer ispreferably a nonwoven fabric layer. In the case that the another layeris provided on an outer side of the first nonwoven fabric layer, it ispreferred that the another layer is joined to the first nonwoven fabriclayer only at the first joining part by heat-embossing.

The nonwoven fabric laminate may further comprise a fourth nonwovenfabric layer in addition to the first nonwoven fabric layer, the secondnonwoven fabric layer and the third nonwoven fabric layer. In this case,the first nonwoven fabric layer, the second nonwoven fabric layer, thethird nonwoven fabric layer and the fourth nonwoven fabric layer arelaminated in this order. In the case that the nonwoven fabric laminatecomprises the fourth nonwoven fabric layer, it is preferred that thefirst nonwoven fabric layer, the second nonwoven fabric layer, the thirdnonwoven fabric layer and the fourth nonwoven fabric layer are joined toeach other at the first joining part by heat-embossing, and the secondnonwoven fabric layer and the third nonwoven fabric layer are furtherjoined to each other at second joining part by heat-embossing. When thenonwoven fabric laminate is configured in this manner, hand feeling ofboth the first nonwoven fabric layer side and the fourth nonwoven fabriclayer side of the nonwoven fabric laminate can be made good. That is,the first nonwoven fabric layer is joined to the second nonwoven fabriclayer only at the first joining part and the fourth nonwoven fabriclayer is joined to the third nonwoven fabric layer only at the firstjoining part, whereby joining parts formed by heat-embossing aredecreased and hand feeling of both the first nonwoven fabric layer sideand the fourth nonwoven fabric layer side of the nonwoven fabriclaminate can be made good. Meanwhile, the second nonwoven fabric layerand the third nonwoven fabric layer are joined at both the first joiningpart and the second joining part by heat-embossing, whereby strength ofthe nonwoven fabric laminate can be increased. In addition, integrity ofthe nonwoven fabric layers constituting the nonwoven fabric laminate isensured by heat-embossing the first to fourth nonwoven fabric layerstogether at the first joining part.

Heat-embossing patterns of the first joining part and the second joiningpart are not particularly limited. The first joining part and the secondjoining part may be disposed in a scattered point pattern in any shapeor may be disposed in a lattice pattern or a linear pattern. In the casethat the first joining part and the second joining part are disposed ina scattered point pattern, each single shape of the first joining partand the second joining part is not particularly limited and may becircular, elliptical, polygonal, wavy, starlike or the other.Arrangement patterns of the first joining part and the second joiningpart are not also particularly limited, and the first joining part andthe second joining part may be provided in a regular pattern or in arandom pattern. In the case that the first joining part and the secondjoining part are disposed in a lattice pattern or a linear pattern, eachline constituting the lattice pattern or the linear pattern may be anyform such as a straight line, a wavy line, a zigzag line or the like,and the each line is preferably provided over a substantially entirearea of the nonwoven fabric layer in one direction or in both onedirection and another direction in the plane. In any case, at least aportion of the second joining part is preferably provided at a regionbetween the first joining parts, and thus, it is preferably providedthat a region where the first joining part is provided is overlappedwith a region where the second joining part is provided.

The first joining part is preferably disposed in a scattered pointpattern. When the first joining part is disposed in a scattered pointpattern, it is possible to decrease the heat-embossed area in the firstnonwoven fabric layer, thereby improving hand feeling of the nonwovenfabric laminate. Moreover, by providing the first joining part in ascattered point pattern, the first nonwoven fabric layer can be formedso as to float to the second nonwoven fabric layer in more area, therebyimproving the visual shielding property through the nonwoven fabriclaminate. From the viewpoint of improving appearance of the nonwovenfabric laminate, it is preferred that a plurality of the first joiningparts are aligned in both one direction and another direction in thenonwoven fabric laminate. Here, one direction and another direction inthe nonwoven fabric laminate means one direction and another directionin a plane including the nonwoven fabric laminate.

The second joining part is preferably disposed in a scattered pointpattern. When the second joining part is disposed in a scattered pointpattern, it becomes easy to ensure flexibility of the nonwoven fabriclaminate even though the second joining part is formed as well as thefirst joining part in the second nonwoven fabric layer and the thirdnonwoven fabric layer. As a result, even when the nonwoven fabriclaminate is distorted in use, the nonwoven fabric laminate easilyfollows the distortion smoothly. From the viewpoint that the nonwovenfabric laminate easily deforms against an external force smoothly, it ispreferred that a plurality of the second joining parts are aligned inboth one direction and another direction in the nonwoven fabriclaminate.

It is preferred that a plurality of the first joining parts are disposedso as to be aligned in one direction and another direction in thenonwoven fabric laminate, and a plurality of the second joining partsare disposed so as to be aligned in one direction and another directionin the nonwoven fabric laminate at a region except the first joiningparts being disposed. When the first joining parts and the secondjoining parts are disposed in this manner, hand feeling of the nonwovenfabric laminate is improved and the nonwoven fabric laminate easilydeforms against an external force smoothly. Moreover, the visualshielding property through the nonwoven fabric laminate is improved andthe appearance of the nonwoven fabric laminate is also improved.

It is preferred that an area of the one (single) first joining part islarger than that of the one (single) second joining part. Thus, it ispreferred that the first joining part is disposed in a shape that islarger than the second joining part. By providing the first joining partin this manner, each of the nonwoven fabric layers is firmly joined atthe first joining part, thereby increasing integrity of the nonwovenfabric laminate.

It is preferred that a number of the second joining part is larger thanthat of the first joining part. When the second joining part is providedlarger in number than the first joining part, the area where the secondnonwoven fabric layer and the third nonwoven fabric layer areheat-embossed can be increased, whereby the strength of the nonwovenfabric laminate is enhanced. The numbers of the first joining parts andthe second joining parts may be measured by counting numbers of thefirst joining parts and the second joining parts formed in a certainarea (e.g., an area of 5 cm×5 cm). Further, the second joining part ispreferably provided with a smaller shape and larger in number than thefirst joining part, and by providing the second joining part in thismanner, it becomes easy to ensure the flexibility of the second nonwovenfabric layer and the third nonwoven fabric layer.

It is preferred that a total area of the first joining part is smallerthan that of the second joining part. When the first joining part andthe second joining part are provided in this manner, it becomes easy toimprove hand feeling of the nonwoven fabric laminate while increasingstrength of the nonwoven fabric laminate. The total area of the firstjoining part can be determined by measuring percentage of the embossedarea by the first joining part in the first nonwoven fabric layer, andthe total area of the second joining part can be determined by measuringpercentage of the embossed area by the first joining part and the secondjoining part and subtracting the percentage of the embossed area by thefirst joining part therefrom.

The first joining part and the second joining part may have a same shapeto each other or may have a different shape from each other. Forexample, both of the first joining part and the second joining part maybe formed in a circular shape. In this case, it becomes easy to providea desired physical property isotropically to the nonwoven fabriclaminate.

Meanwhile, in the case where the first joining part and the secondjoining part are formed in a different shape from each other, it ispossible, for example, to determine the shape of the first joining partfrom the viewpoint of ensuring the integrity of the nonwoven fabriclaminate and determine the shape of the second joining part from theviewpoint of increasing the strength of the nonwoven fabric laminate.Thus, it becomes possible to give a desired physical property to thenonwoven fabric laminate in accordance with an actual usage. Forexample, in the case that the nonwoven fabric laminate tends to have aload in a specific direction in use, when the first joining part isformed in an elongated shape in the specific direction and the secondjoining part is formed in a circular shape, the integrity of thenonwoven fabric laminate can be ensured even in the state where thenonwoven fabric laminate have a load in the specific direction, andfurther, the strength of the entire nonwoven fabric laminate can beincreased.

Types of a nonwoven fabric constituting each of the nonwoven fabriclayer is not particularly limited, and a spunbonded nonwoven fabric, anair-through nonwoven fabric, a point-bonded nonwoven fabric, a meltblownnonwoven fabric, an air-laid nonwoven fabric or the like can beemployed. In the case where the nonwoven fabric laminate is applied to,for example, absorbent articles, covers, bags, protective clothing andsheets as described above, the nonwoven fabric laminate preferably hasbreathability, and in this case, each of the nonwoven fabric layer ispreferably made of a spunbonded nonwoven fabric or an air-throughnonwoven fabric. When each of the nonwoven fabric layer is made of suchnonwoven fabric, breathability of the nonwoven fabric laminate isincreased and internal humidity is easily decreased.

As a specific constitution of the nonwoven fabric layers, it ispreferred that each of the first nonwoven fabric layer, the secondnonwoven fabric layer and the third nonwoven fabric layer is made of aspunbonded nonwoven fabric, for example. When the nonwoven fabriclaminate is constituted in this manner, breathability of the nonwovenfabric laminate is increased, and further, since a spunbonded nonwovenfabric is able to be formed relatively thin, the nonwoven fabric layerscan be firmly joined to each other by joining the first nonwoven fabriclayer, the second nonwoven fabric layer and the third nonwoven fabriclayer to each other at the first joining part by heat-embossing, wherebyintegrity of the nonwoven fabric laminate is enhanced. In this case, ifthe nonwoven fabric laminate comprises the fourth nonwoven fabric layer,the fourth nonwoven fabric layer is also preferably made of a spunbondednonwoven fabric.

As a specific constitution of the nonwoven fabric layers, it is alsopreferred that the first nonwoven fabric layer is made of an air-throughnonwoven fabric and the second and third nonwoven fabric layers are madeof a spunbonded nonwoven fabric. An air-through nonwoven fabric isrelatively bulky and has a good texture, and hence, when the firstnonwoven fabric layer located on an outer surface of the nonwoven fabriclaminate is made of an air-through nonwoven fabric, hand feeling of thenonwoven, fabric laminate is improved while increasing breathability ofthe nonwoven fabric laminate. In this case, if the nonwoven fabriclaminate comprises the fourth nonwoven fabric layer, the fourth nonwovenfabric layer is preferably made of an air-through nonwoven fabric aswell as the first nonwoven fabric layer.

A spunbonded nonwoven fabric and an air-through nonwoven fabric can beformed such that fibers constituting the nonwoven fabric orient in onedirection. In the case that the first nonwoven fabric layer, the secondnonwoven fabric layer and the third nonwoven fabric layer (or furtherthe fourth nonwoven fabric layer) are made of a spunbonded nonwovenfabric or an air-through nonwoven fabric, the first joining partpreferably has a shape that is shorter in an orientation direction offibers constituting the nonwoven fabric than in its orthogonaldirection. A nonwoven fabric in which constituent fibers are oriented inone direction is formed that breaking strength becomes weak with respectto a direction orthogonal to the orientation direction of theconstituent fibers; however, when the first joining part is formed in ashape that is shorter in the fiber orientation direction of the nonwovenfabric (that is, longer in the direction orthogonal to the fiberorientation direction of the nonwoven fabric), the constituent fibers ofthe nonwoven fabric are firmly joined together by heat-embossing at thefirst joining part, whereby breaking strength of the nonwoven fabric canbe increased. As a result, even when the nonwoven fabric laminate isstretched, integrity of the nonwoven fabric laminate is easilymaintained. In this case, it is preferred that constituent fibers in allof the nonwoven fabric layers are oriented in the same direction.

The fiber orientation direction of a spunbonded nonwoven fabric or anair-through nonwoven fabric can be determined by observing a surface ofthe nonwoven fabric with a microscope or the like. A spunbonded nonwovenfabric is formed by, for example, melting a polymer material, extrudingfrom a spinneret to be stretched, and collecting on a conveyor belt orthe like to form a web; and on this occasion, the web (fibers) collectedon the conveyer belt is arranged along a traveling direction of theconveyer belt. Therefore, in this case, the web (fibers) comes to beoriented in the traveling direction (MD direction) of the conveyer belt.In the air-through nonwoven fabric, the orientation direction of theconstituent fibers can be arranged by appropriately setting a collectionmethod of raw short fibers in forming a fiber aggregate or afiber-opening method in forming a web, upon manufacturing the nonwovenfabric.

The second joining part also may be formed to have a shape that isshorter in the orientation direction of fibers constituting the nonwovenfabric than in its orthogonal direction. In this case, strength of thenonwoven fabric, with respect to the orthogonal direction to fiberorientation direction, of the second nonwoven fabric layer and the thirdnonwoven fabric layer can be further increased.

Regarding the first joining part and the second joining part, examplesof the elongated shape in one direction include an ellipse shape, arectangle shape, a rhombus shape, a wave shape, a radiation shape andthe like. For example, in the case of an elliptical shape, it may beprovided in the nonwoven fabric laminate so that the long axis directioncorresponds to the one direction.

Fineness of each of the nonwoven fabric layers is not particularlylimited; however, it is preferred that fineness of the first nonwovenfabric layer is larger than those of second nonwoven fabric layer andthe third nonwoven fabric layer. In the case that the nonwoven fabriclayer comprises the fourth nonwoven fabric layer, it is preferred thatfineness of the fourth nonwoven fabric layer is also larger than thoseof the second nonwoven fabric layer and the third nonwoven fabric layer.When the first nonwoven fabric layer or the fourth nonwoven fabric layeris formed in this manner, void ratio of the first nonwoven fabric layeror the fourth nonwoven fabric layer tends to increase and the firstnonwoven fabric layer or the fourth nonwoven fabric layer is formedbulky, resulting in easily improving hand feeling of the nonwoven fabriclaminate.

Examples of the nonwoven fabric laminate is described below, referringto FIGS. 1 and 2. However, the nonwoven fabric laminate of the presentinvention is not limited to the embodiments shown in the drawings.

FIG. 1 shows a perspective view of a nonwoven fabric laminate in whichthe first nonwoven fabric layer, the second nonwoven fabric layer andthe third nonwoven fabric layer are laminated. A nonwoven fabriclaminate 1 shown in FIG. 1 comprises a first nonwoven fabric layer 2, asecond nonwoven fabric layer 3 and a third nonwoven fabric layer 4, andthe first nonwoven fabric layer 2, the second nonwoven fabric layer 3and the third nonwoven fabric layer 4 are laminated in this order. Inthe nonwoven fabric laminate 1, the first nonwoven fabric layer 2 formsa surface which a user mainly touches by hand.

The first nonwoven fabric layer 2, the second nonwoven fabric layer 3and the third nonwoven fabric layer 4 are joined to each other at firstjoining parts 6 by heat-embossing, and the second nonwoven fabric layer3 and the third nonwoven fabric layer 4 are further joined to each otherat second joining parts 7 by heat-embossing. In the nonwoven fabriclaminate 1, as the nonwoven fabric layers are joined together in thismanner, strength of the nonwoven fabric laminate 1 can be increased bythe heat-embossed first and second joining parts 6,7, while hand feelingof the first nonwoven fabric layer 2 side of the nonwoven fabriclaminate 1 can be improved since the first nonwoven fabric layer 2 isheat-embossed only at the first joining parts 6. Further, the nonwovenfabric laminate 1 is configured such that the joining pattern of thefirst nonwoven fabric layer 2 with the second nonwoven fabric layer 3 isdifferent from the joining pattern of the second nonwoven fabric layer 3with the third nonwoven fabric layer 4, and therefore, interlayerdistances between the respective nonwoven fabric layers are variouslychanged, whereby a visual shielding property of the nonwoven fabriclaminate 1 can be increased.

It is preferred that the first joining parts 6 and the second joiningparts 7 are respectively arranged in a matrix in a plane, as shown inFIG. 1. That is, it is preferred that a plurality of the first joiningparts 6 are disposed so as to be aligned in one direction and anotherdirection in the nonwoven fabric laminate 1, and a plurality of thesecond joining parts 7 are disposed so as to be aligned in one directionand another direction in the nonwoven fabric laminate 1 at a regionexcept the first joining parts 6 being formed. When the first joiningparts 6 and the second joining parts 7 are formed in this manner, thevisual shielding property of the nonwoven fabric laminate 1 is increasedand the appearance of the nonwoven fabric laminate 1 is improved, aswell as hand feeling of the nonwoven fabric laminate 1 is enhanced. Inaddition, the nonwoven fabric laminate 1 comes to easily deform againstan external force smoothly, thereby improving handleability of thenonwoven fabric laminate 1.

The first joining part 6 and the second joining part 7 are preferablyformed as follows. That is, the first joining parts 6 are preferablyformed such that an area of the one first joining part 6 is larger thanthat of the one second joining part 7. Meanwhile, it is preferred that atotal area of the first joining parts 6 is smaller than that of thesecond joining parts 7. Therefore, it is preferred that a number of thesecond joining part 7 is larger than that of the first joining part 6.

In FIG. 1, the first joining part 6 and the second joining part 7 have asame shape (a circular shape) to each other; however, the first joiningpart 6 and the second joining part 7 may have a different shape fromeach other. Also in FIG. 1, the first joining parts 6 are formed in auniform shape and the second joining parts 7 are formed in a uniformshape; however, the first joining parts 6 may be formed in a pluralityof various shapes and the second joining parts 7 may be also formed in aplurality of various shapes. Alternatively, the first joining part 6 andthe second joining part 7 may be formed in a lattice shape or a linearshape (for example, a wavy shape or a zigzag line shape).

FIG. 2 shows a perspective view of a nonwoven fabric laminate in whichthe first nonwoven fabric layer, the second nonwoven fabric layer, thethird nonwoven fabric layer and the fourth nonwoven fabric layer. In theexplanation of the nonwoven fabric laminate shown in FIG. 2,explanations overlapping the above description regarding the FIG. 1 areomitted.

A nonwoven fabric laminate 1 shown in FIG. 2 comprises a first nonwovenfabric layer 2, a second nonwoven fabric layer 3, a third nonwovenfabric layer 4 and a fourth nonwoven fabric layer 5, and the firstnonwoven fabric layer 2, the second nonwoven fabric layer 3, the thirdnonwoven fabric layer 4 and the fourth nonwoven fabric layer 5 arelaminated in this order. The first nonwoven fabric layer 2, the secondnonwoven fabric layer 3, the third nonwoven fabric layer 4 and thefourth nonwoven fabric layer 5 are joined to each other at first joiningparts 6 by heat-embossing, and the second nonwoven fabric layer 3 andthe third nonwoven fabric layer 4 are further joined to each other atsecond joining parts 7 by heat-embossing. In the nonwoven fabriclaminate 1, as the nonwoven fabric layers are joined together in thismanner, strength of the nonwoven fabric laminate 1 is increased by theheat-embossed first and second joining parts 6,7, while hand feeling ofboth the first nonwoven fabric layer 2 side and the fourth nonwovenfabric layer 5 side of the nonwoven fabric laminate 1 can be improvedsince the first nonwoven fabric layer 2 and the fourth nonwoven fabriclayer 5 are heat-embossed only at the first joining parts 6.

Process for Producing Nonwoven Fabric Laminate

Next, a process for producing the nonwoven fabric laminate of thepresent invention is explained. A process for producing a nonwovenfabric laminate comprises the steps in the sequence set forth: forming athird nonwoven fabric layer (a third nonwoven fabric layer-formingstep); forming a second nonwoven fabric layer on the third nonwovenfabric layer (a second nonwoven fabric layer-forming step);heat-embossing the second nonwoven fabric layer and the third nonwovenfabric layer to join to each other at a second joining part (a secondjoining part-forming step); forming a first nonwoven fabric layer on thesecond nonwoven fabric layer (a first nonwoven fabric layer-formingstep); and heat-embossing the first nonwoven fabric layer, the secondnonwoven fabric layer and the third nonwoven fabric layer to join toeach other at a first joining part (a first joining part-forming step).According to the process for producing a nonwoven fabric laminate of thepresent invention, the nonwoven fabric laminate of the present inventioncan be easily manufactured.

In the third nonwoven fabric layer-forming step, the third nonwovenfabric layer is formed by using a conventionally-known method dependingon the type of the nonwoven fabric constituting the third nonwovenfabric layer.

In the second nonwoven fabric layer-forming step, the second nonwovenfabric layer is formed on the third nonwoven fabric layer by using aconventionally-known method depending on the type of the nonwoven fabricconstituting the second nonwoven fabric layer. The second nonwovenfabric layer is formed on one surface of the third nonwoven fabriclayer. In the second nonwoven fabric layer-forming step, the secondnonwoven fabric layer which was already formed in a layer may be stackedon the third nonwoven fabric layer, or the second nonwoven fabric layermay be formed in a layer on the third nonwoven fabric layer. Forexample, in the case where the second nonwoven fabric layer is made of aspunbonded nonwoven fabric or a meltblown nonwoven fabric, the secondnonwoven fabric layer can be formed directly on the third nonwovenfabric layer by the latter method, that is, collecting melted fibersonto the third nonwoven fabric layer.

In the second joining part-forming step, the second nonwoven fabriclayer and the third nonwoven fabric layer are heat-embossed in a stackedstate to be joined to each other. By heat-embossing the second nonwovenfabric layer and the third nonwoven fabric layer, a second joining partwhere the heat-emboss was applied is formed and the second nonwovenfabric layer and the third nonwoven fabric layer are joined to eachother at the second joining part. The heat-emboss can be formed byinserting the second nonwoven fabric layer and the third nonwoven fabriclayer in the stacked state between two rolls to be conveyed, and on thisoccasion, a heat-embossing roll (that is a roll having a predeterminedembossed pattern on its surface and being heatable) may be used for atleast one of the rolls. Alternatively, heat-embossing can be alsoconducted by bringing a ultrasonic transducer contact with the secondnonwoven fabric layer and the third nonwoven fabric layer of the stackedstate and pressurizing.

In the first nonwoven fabric layer-forming step, the first nonwovenfabric layer is formed on the second nonwoven fabric layer by using aconventionally-known method depending on the type of the nonwoven fabricconstituting the first nonwoven fabric layer. The first nonwoven fabriclayer is formed on one surface of the second nonwoven fabric layer (thatis the surface opposite to the third nonwoven fabric layer). In thefirst nonwoven fabric layer-forming step, the first nonwoven fabriclayer which was already formed in a layer may be stacked on the secondnonwoven fabric layer, or the first nonwoven fabric layer may be formedin a layer on the second nonwoven fabric layer. For example, in the casewhere the first nonwoven fabric layer is made of a spunbonded nonwovenfabric or a meltblown nonwoven fabric, the first nonwoven fabric layercan be formed directly on the second nonwoven fabric layer by the lattermethod, that is, collecting melted fibers onto the second nonwovenfabric layer. By conducting the first nonwoven fabric layer-formingstep, the first nonwoven fabric layer is formed on the laminate of thesecond nonwoven fabric layer and the third nonwoven fabric layer.

In the first joining part-forming step, the first nonwoven fabric layer,the second nonwoven fabric layer and the third nonwoven fabric layer areheat-embossed collectively in a stacked state to be joined to eachother. By heat-embossing the first nonwoven fabric layer, the secondnonwoven fabric layer and the third nonwoven fabric layer, a firstjoining part is formed at a part where the heat-emboss was applied andthe first nonwoven fabric layer, the second nonwoven fabric layer andthe third nonwoven fabric layer are joined to each other at the firstjoining part. By conducting the first joining part-forming step, thenonwoven fabric laminate in which the first nonwoven fabric layer, thesecond nonwoven fabric layer and the third nonwoven fabric layer arejoined to each other at the first joining part and the second joiningpart. The first joining part is formed so as not to overlap with atleast a portion of the second joining part. The first joining part canbe formed by using a heat-embossing roll, as with the second joiningpart.

In the case of producing the nonwoven fabric laminate comprising thefourth nonwoven fabric layer in the production process of the presentinvention, it is preferred that the fourth nonwoven fabric layer isformed under the third nonwoven fabric layer as well as the firstnonwoven fabric layer is formed on the second nonwoven fabric layer inthe first nonwoven fabric layer-forming step. This step is referred toas a first and fourth nonwoven fabric layers forming step.

In the first and fourth nonwoven fabric layers forming step, the firstnonwoven fabric layer is formed on the second nonwoven fabric layer asdescribed above. Thus, the first nonwoven fabric layer is formed on onesurface of the second nonwoven fabric layer (that is the surfaceopposite to the third nonwoven fabric layer). The fourth nonwoven fabriclayer is formed by using a conventionally-known method depending on thetype of the nonwoven fabric constituting the fourth nonwoven fabriclayer. The fourth nonwoven fabric layer is formed on the other surfaceof the third nonwoven fabric layer (that is the surface opposite to thesecond nonwoven fabric layer). In the first and fourth nonwoven fabriclayers forming step, the fourth nonwoven fabric layer which was alreadyformed in a layer may be disposed under the third nonwoven fabric layer,or the fourth nonwoven fabric layer may be formed in a layer on thethird nonwoven fabric layer of the laminate comprising the secondnonwoven fabric layer and the third nonwoven fabric layer (and mayfurther comprise the first nonwoven fabric layer), that is disposed inthe state where the third nonwoven fabric layer is placed at the topside. For example, in the case where the fourth nonwoven fabric layer ismade of a spunbonded nonwoven fabric or a meltblown nonwoven fabric, thefourth nonwoven fabric layer can be formed directly on the thirdnonwoven fabric layer by the latter method, that is, collecting meltedfibers onto the third nonwoven fabric layer. By conducting the first andfourth nonwoven fabric layers forming step, the first nonwoven fabriclayer is formed on the laminate of the second nonwoven fabric layer andthe third nonwoven fabric layer and the fourth nonwoven fabric layer isformed under the laminate of the second nonwoven fabric layer and thethird nonwoven fabric layer. In the first and fourth nonwoven fabriclayers forming step, the order of forming the first nonwoven fabriclayer and the fourth nonwoven fabric layer is not particularly limited.

The first joining part-forming step is conducted, following the firstand fourth nonwoven fabric layers forming step. In the first joiningpart-forming step, the first nonwoven fabric layer, the second nonwovenfabric layer, the third nonwoven fabric layer and the fourth nonwovenfabric layer are heat-embossed collectively in a stacked state to bejoined to each other. By heat-embossing the first nonwoven fabric layer,the second nonwoven fabric layer, the third nonwoven fabric layer andthe fourth nonwoven fabric layer, a first joining part is formed at apart where the heat-emboss was applied and the first nonwoven fabriclayer, the second nonwoven fabric layer, the third nonwoven fabric layerand the fourth nonwoven fabric layer are joined to each other at thefirst joining part. By conducting the first joining part-forming step,the nonwoven fabric laminate in which the first nonwoven fabric layer,the second nonwoven fabric layer, the third nonwoven fabric layer andthe fourth nonwoven fabric layer are joined to each other at the firstjoining part and the second joining part. The first joining part isformed so as not to overlap with at least a portion of the secondjoining part. The first joining part can be formed by using aheat-embossing roll, as with the second joining part.

If the nonwoven fabric laminate obtained as described above is acontinuous body, the continuous body may be cut into an individualnonwoven fabric laminate. Alternatively, the continuous body of thenonwoven fabric laminate may be supplied to the subsequent manufacturingprocess to, continuously produce nonwoven products (e.g., absorbentarticles or the like).

In the process for producing the nonwoven fabric laminate of the presentinvention, the first nonwoven fabric layer, the second nonwoven fabriclayer and the third nonwoven fabric layer are preferably made of aspunbonded nonwoven fabric or a meltblown nonwoven fabric. In the casewhere the nonwoven fabric laminate comprises the fourth nonwoven fabriclayer, the fourth nonwoven fabric layer is also preferably made of aspunbonded nonwoven fabric or a meltblown nonwoven fabric. In this case,all of the nonwoven fabric layers may be spunbonded nonwoven fabrics ormeltblown nonwoven fabrics, or a part of the nonwoven fabric layers maybe a spunbonded nonwoven fabric and the other part of the nonwovenfabric layers may be a meltblown nonwoven fabric. When the firstnonwoven fabric layer, the second nonwoven fabric layer and the thirdnonwoven fabric layer are made of a spunbonded nonwoven fabric or ameltblown nonwoven fabric, the second nonwoven fabric layer (or thefirst nonwoven fabric layer) can be formed into a web directly on thethird nonwoven fabric layer (or the second nonwoven fabric layer), andso the nonwoven fabric laminate can be easily manufactured. Further,when the fourth nonwoven fabric layer is made of a spunbonded nonwovenfabric or a meltblown nonwoven fabric, the fourth nonwoven fabric layercan be formed into a web directly on the third nonwoven fabric layer,and so the nonwoven fabric laminate can be easily manufactured. In thecase that the nonwoven fabric laminate is applied to an exterior sheetof an absorbent article as described below, the first nonwoven fabriclayer, the second nonwoven fabric layer and the third nonwoven fabriclayer are preferably made of a spunbonded nonwoven fabric.

Preferred embodiments relating to the shapes and arrangements of thefirst joining part and the second joining part are the same as describedabove. For example, it is preferred that a plurality of the firstjoining parts or the second joining parts are disposed so as to bealigned in one direction and another direction, and it is preferred thatan area of the one (single) first joining part is larger than that ofthe one (single) second joining part or a number of the second joiningpart is larger than that of the first joining part, and the firstjoining part and the second joining part may have a different shape fromeach other. In the case where the first nonwoven fabric layer, thesecond nonwoven fabric layer and the third nonwoven fabric layer aremade of a spunbonded nonwoven fabric, the first joining part ispreferably formed to have a shape that is shorter in the fiberorientation direction of the nonwoven fabric than in its orthogonaldirection. The second joining part may be formed in this manner.

The nonwoven fabric laminate of the present invention may be obtained bythe above production process, that is, it comprises the first nonwovenfabric layer, the second nonwoven fabric layer and the third nonwovenfabric layer, and may be obtained by a process for producing a nonwovenfabric laminate comprising the steps in the sequence set forth: formingthe second nonwoven fabric layer on the third nonwoven fabric layer;heat-embossing the second nonwoven fabric layer and the third nonwovenfabric layer to join to each other at the second joining part; formingthe first nonwoven fabric layer on the second nonwoven fabric layer; andheat-embossing the first nonwoven fabric layer, the second nonwovenfabric layer and the third nonwoven fabric layer to join to each otherat the first joining part. Or, the nonwoven fabric laminate of thepresent invention comprises the first nonwoven fabric layer, the secondnonwoven fabric layer, the third nonwoven fabric layer and the fourthnonwoven fabric layer, and may be obtained by a process for producing anonwoven fabric laminate comprising the steps in the sequence set forth:forming the second nonwoven fabric layer on the third nonwoven fabriclayer; heat-embossing the second nonwoven fabric layer and the thirdnonwoven fabric layer to join to each other at the second joining part;forming the first nonwoven fabric layer on the second nonwoven fabriclayer and the fourth nonwoven fabric layer under the third nonwovenfabric layer; and heat-embossing the first nonwoven fabric layer, thesecond nonwoven fabric layer, the third nonwoven fabric layer and thefourth nonwoven fabric layer to join to each other at the first joiningpart. Details of each step are the same as described above.

An example of the process for producing a nonwoven fabric laminate ofthe present invention is described below, referring to FIG. 3. FIG. 3shows a schematic view of a process for producing the nonwoven fabriclaminate in which the first nonwoven fabric layer, the second nonwovenfabric layer and the third nonwoven fabric layer are made of aspunbonded nonwoven fabric.

In the third nonwoven fabric layer-forming step 61, the third nonwovenfabric layer 43 is formed. In FIG. 3, plural rows of a molten polymermaterial are continuously fed from a fiber supply device 42 andcollected on a conveyer belt 41 conveyed in the direction w, therebyforming the third nonwoven fabric layer 43 of a spunbonded nonwovenfabric.

In the second nonwoven fabric layer-forming step 62, the second nonwovenfabric layer 45 is formed on the third nonwoven fabric layer 43. In FIG.3, plural rows of a molten polymer material are continuously fed from afiber supply device 44 and collected on the third nonwoven fabric layer43 conveyed in the direction w, thereby forming the second nonwovenfabric layer 45 of a spunbonded nonwoven fabric on the third nonwovenfabric layer 43.

In the second joining part-forming step 63, the second nonwoven fabriclayer 45 and the third nonwoven fabric layer 43 are heat-embossed to bejoined to each other at second joining parts. In FIG. 3, the secondnonwoven fabric layer 45 and the third nonwoven fabric layer 43 in astacked state are inserted between a heat-embossing roll 46 and a flatroll 47, thereby joining the second nonwoven fabric layer 45 and thethird nonwoven fabric layer 43 to each other by heat-embossing. Apredetermined embossing pattern is formed on the surface of theheat-embossing roll 46, and the second nonwoven fabric layer 45 and thethird nonwoven fabric layer 43 are joined to each other at the secondjoining part formed in that pattern.

In the first nonwoven fabric layer-forming step 64, the first nonwovenfabric layer 49 is formed on the second nonwoven fabric layer 45. InFIG. 3, plural rows of a molten polymer material are continuously fedfrom a fiber supply device 48 and collected on the laminate of the thirdnonwoven fabric layer 43 and the second nonwoven fabric layer 45conveyed in the direction w, thereby forming the first nonwoven fabriclayer 49 of a spunbonded nonwoven fabric on the second nonwoven fabriclayer 45.

In the first joining part-forming step 65, the first nonwoven fabriclayer 49, the second nonwoven fabric layer 45 and the third nonwovenfabric layer 43 are heat-embossed to be joined to each other at firstjoining parts. In FIG. 3, the first nonwoven fabric layer 49, the secondnonwoven fabric layer 45 and the third nonwoven fabric layer 43 in astacked state are inserted between a heat-embossing roll 50 and a flatroll 51, thereby joining the first nonwoven fabric layer 49, the secondnonwoven fabric layer 45 and the third nonwoven fabric layer 43 to eachother by heat-embossing. A predetermined embossing pattern is formed onthe surface of the heat-embossing roll 50, and the first nonwoven fabriclayer 49, the second nonwoven fabric layer 45 and the third nonwovenfabric layer 43 are joined to each other at the first joining partformed in that pattern. As a result, the nonwoven fabric laminate 52 (acontinuous body) in which the first nonwoven fabric layer 49, the secondnonwoven fabric layer 45 and the third nonwoven fabric layer 43 areintegrally joined to each other at the first and second joining parts isobtained.

Absorbent Article

Next, an absorbent article of the present invention is explained. Anabsorbent article of the present invention comprises an exterior sheetformed of the nonwoven fabric laminate of the present invention. Byemploying the nonwoven fabric laminate of the present invention for theexterior sheet of an absorbent article, hand feeling of the exteriorsheet can be improved while strength thereof is increased. Examples ofthe absorbent article include a disposable diaper, an incontinence pad(including a light incontinence pad) and a sanitary napkin.

The absorbent article has a skin-facing side and an outer side withrespect to a thickness direction of the absorbent article. A skin-facingside of the absorbent article means a side close to wearer's skin inwearing the absorbent article and an outer side of the absorbent articlemeans a side opposite to a wearer in wearing the absorbent article.

The exterior sheet is located on an outer side of the absorbent article.For example, the absorbent article comprises a top sheet, a back sheetand an absorbent core provided therebetween, and in the case where theback sheet is disposed on an outer side of the absorbent article, theback sheet corresponds to the exterior sheet. In the case where theabsorbent article is a pants-type disposable diaper, the pants-typedisposable diaper may be formed such that an absorbent body comprising atop sheet, a back sheet and an absorbent core provided therebetween isdisposed on a skin-facing side of a pants member that is formed in apants shape; and in this case, at least a portion of the pants membermay be composed of the exterior sheet. As just described, it ispreferred that the exterior sheet is provided so as to constitute theouter side the absorbent article.

A shape of the absorbent article is not particularly limited. In thecase where the absorbent article is an incontinence pad, examples of theshape of the absorbent article include a substantially rectangularshape, an hourglass shape, a center nipped-in gourd shape, a battledoreshape and others.

In the case where the absorbent article is a disposable diaper, theabsorbent article has, for example, a front part, a rear part, and acrotch part positioned therebetween and provided with an absorbent core.The disposable diaper may be an open-type (tape-type) disposable diaperthat is provided with a pair of fastening members on left and rightsides of a rear part and is formed into a pants shape by using thefastening members in wearing, or the disposable diaper may be apants-type disposable diaper that is formed in a pants shape and has awaist opening and a pair of leg openings. The disposable diaper maycomprise, for example, an exterior member having a front part, a rearpart and a crotch part positioned therebetween and an absorbent bodycomprising a top sheet, a back sheet and an absorbent core providedtherebetween, wherein the absorbent body is disposed on a skin-facingside of the exterior member. Or, the disposable diaper may be formedsuch that a laminate comprising a top sheet, a back sheet and anabsorbent core provided therebetween has a front part, a rear part and acrotch part positioned therebetween. Here, the front part means a partapplied to an abdomen side of the wearer, the rear part means a partapplied to a back side of the wearer, and the crotch part means a partpositioned between the front part and the rear part and applied to acrotch of the wearer, in wearing the disposable diaper.

The exterior sheet is composed of the nonwoven fabric laminate of thepresent invention. In the nonwoven fabric laminate of the presentinvention, the first nonwoven fabric layer is preferably a surface whicha user mainly touches by hand; and therefore, in the case of applying tothe exterior sheet of the absorbent article, the first nonwoven fabriclayer preferably located on an outer side of the absorbent article.Thus, it is preferred that the exterior sheet comprises the firstnonwoven fabric layer, the second nonwoven fabric layer and the thirdnonwoven fabric layer from the outer side of the absorbent article, thefirst nonwoven fabric layer, the second nonwoven fabric layer and thethird nonwoven fabric layer are joined to each other at the firstjoining part by heat-embossing, and the second nonwoven fabric layer andthe third nonwoven fabric layer are further joined to each other at thesecond joining part by heat-embossing.

Since the exterior sheet is constituted in this manner, both strengthand hand feeling can be enhanced. That is, in the exterior sheet, thesecond nonwoven fabric layer and the third nonwoven fabric layer, thatare located close to the skin-facing side, are joined to each other atboth the first joining part and the second joining part byheat-embossing, whereby strength of the exterior sheet can be increased.And, the first nonwoven fabric layer is provided on the outer side ofthe second sheet and is joined to the second nonwoven fabric layer onlyat the first joining part, whereby joining parts formed byheat-embossing are decreased and hand feeling of the exterior sheetlocated on the outer side of the absorbent article can be made good. Inaddition, since the exterior sheet is formed such that the joiningpattern of the first nonwoven fabric layer with the second nonwovenfabric layer is different from the joining pattern of the secondnonwoven fabric layer with the third nonwoven fabric layer, interlayerdistances between the nonwoven fabric layers are variously changed, thatmakes degree of transmission or diffusion of light through the exteriorsheet uneven properly, whereby a visual shielding property through theexterior sheet can be increased. For example, in the case that anelastic member is disposed to the skin-facing side of the exteriorsheet, the elastic member becomes hardly seen from the outside of theabsorbent article, or in the case that an absorbent core disposed to theskin-facing side of the exterior sheet is colored by absorbingexcrement, the absorbent core can be made less obvious seen from theoutside of the absorbent article.

The exterior sheet is formed by laminating the first nonwoven fabriclayer, the second nonwoven fabric layer and the third nonwoven fabriclayer and is handled as a single sheet member; and thus, no elasticmember is provided between the respective nonwoven fabric layersconstituting the exterior sheet (that is, between the first nonwovenfabric layer and the second nonwoven fabric layer, and between thesecond nonwoven fabric layer and the third nonwoven fabric layer). Inthe exterior sheet, another layer may be provided on the outer side ofthe first nonwoven fabric layer or the skin-facing side of the thirdnonwoven fabric layer; however, the exterior sheet preferably does notcomprise so many layers in view of easily ensuring flexibility andbreathability of the exterior sheet and preferably consists of the firstnonwoven fabric layer, the second nonwoven fabric layer and the thirdnonwoven fabric layer.

Preferred embodiments relating to the arrangement patterns, shapes,sizes and the like of the first joining part and the second joining partare the same as described above. For example, it is preferred that aplurality of the first joining parts are disposed so as to be aligned inone direction and another direction in the exterior sheet, and aplurality of the second joining parts are disposed so as to be alignedin one direction and another direction in the exterior sheet at a regionexcept the first joining parts being disposed. When the first joiningparts and the second joining parts are disposed in such a manner, handfeeling of the exterior sheet is improved, and the exterior sheet easilydeforms against an external force smoothly, that improves wearingfeeling of the absorbent article. In addition, the visual shieldingproperty through the exterior sheet is increased and the appearance ofthe absorbent article is also improved.

Types of a nonwoven fabric constituting each of the nonwoven fabriclayer is not particularly limited, and a spunbonded nonwoven fabric, anair-through nonwoven fabric, a point-bonded nonwoven fabric, a meltblownnonwoven fabric, an air-laid nonwoven fabric or the like can beemployed. Here, the exterior sheet is located on the outer side of theabsorbent article and preferably has breathability, and in this respect,each of the nonwoven fabric layers constituting the exterior sheet ispreferably made of a spunbonded nonwoven fabric or an air-throughnonwoven fabric. When each of the nonwoven fabric layers of the exteriorsheet is made of such nonwoven fabric, breathability of the exteriorsheet is increased and internal humidity is easily decreased in wearingthe absorbent article.

As a specific constitution of the first nonwoven fabric layer, thesecond nonwoven fabric layer and the third nonwoven fabric layerconstituting the exterior sheet, it is preferred that each of the firstnonwoven fabric layer, the second nonwoven fabric layer and the thirdnonwoven fabric layer is made of a spunbonded nonwoven fabric. When theexterior sheet is constituted in this manner, breathability of theexterior sheet is increased, and further, since a spunbonded nonwovenfabric is able to be formed relatively thin, the nonwoven fabric layerscan be firmly joined to each other by joining the first nonwoven fabriclayer, the second nonwoven fabric layer and the third nonwoven fabriclayer to each other at the first joining part by heat-embossing, wherebyintegrity of the exterior sheet is enhanced.

Regarding the first nonwoven fabric layer, the second nonwoven fabriclayer and the third nonwoven fabric layer, it is also preferred that thefirst nonwoven fabric layer is made of an air-through nonwoven fabricand the second and third nonwoven fabric layers are made of a spunbondednonwoven fabric. An air-through nonwoven fabric is relatively bulky andhas a good texture, and hence, when the first nonwoven fabric layerlocated on the outer side of the exterior sheet is made of anair-through nonwoven fabric, hand feeling of the exterior sheet isimproved while increasing breathability of the exterior sheet.

In the case that an elastic member is disposed to the skin-facing sideof the exterior sheet, the visual shielding property of the exteriorsheet can be increased by providing the first joining part as follows,whereby the elastic member becomes hardly seen from the outside of theexterior sheet. That is, it is preferred that an elastic member isdisposed to the skin-facing side of the exterior sheet and the firstjoining part has a shape that is shorter in an extending direction ofthe elastic member than in an orthogonal direction thereof. When thefirst joining part is provided in this manner, many wrinkles extendingin the direction orthogonal to the extending direction of the elasticmember are easily formed in the exterior sheet, and the elastic memberbecomes hardly seen from the outside of the exterior sheet.Specifically, in the present invention, two kinds of joining parts, thefirst joining part and the second joining part, are formed in theexterior sheet as described above, and therefore, a large number of finewrinkles are formed in the exterior sheet and interlayer distancesbetween the respective nonwoven fabric layers are randomly changed,thereby increasing the visual shielding effect of the exterior sheet.

In the case that an elastic member is disposed to the skin-facing sideof the exterior sheet, it is also preferable that a plurality of thefirst joining parts are aligned in the extending direction of theelastic member and an orthogonal direction thereof, and a distancebetween the first joining parts in the extending direction of theelastic member is wider than that in the orthogonal direction thereof.Also in the case that the first joining part is provided in this manner,many wrinkles extending in the direction orthogonal to the extendingdirection of the elastic member tend to be formed in the exterior sheetwhen the elastic member disposed to the skin-facing side of the exteriorsheet contracts, and as a result, the elastic member becomes hardly seenfrom the outside of the exterior sheet.

In the case that the elastic member is disposed to the skin-facing sideof the exterior sheet, the elastic member is preferably adhered to theskin-facing side of the exterior sheet. In addition, the first joiningpart is preferably provided at a region where the elastic member isdisposed in the exterior sheet.

Next, examples of the absorbent article of the present invention isexplained, referring to drawings. However, the absorbent article of thepresent invention is not limited to the embodiments shown in thedrawings.

FIGS. 4 and 5 show an example of the absorbent article of the presentinvention that is applied to an incontinence pad. FIG. 4 shows a planview of a skin-facing side of an incontinence pad, and FIG. 5 shows across-sectional view along a line V-V of the incontinence pad shown inFIG. 4. In the drawings, an arrow x represents a width direction and anarrow y represents a longitudinal direction, and a direction orthogonalto the arrows x and y represents a thickness direction z. Thelongitudinal direction y corresponds to a direction extending in afront-rear direction at a crotch of a wearer when the wearer wears theabsorbent article, and the width direction x means a directionorthogonal to the longitudinal direction y on the same plane as theabsorbent article.

An absorbent article (an incontinence pad) 11 comprises a top sheet 12,a back sheet 13 and an absorbent core 14 provided therebetween. The topsheet 12 is located on a skin-facing side of the absorbent article 11and allows urine and the like excreted from a wearer to permeatethrough. The urine and the like which has passed through the top sheet12 is accommodated in the absorbent core 14. The back sheet 13 islocated on an outer side of the absorbent article 11 and prevents theexcrement from permeating outside. In the absorbent article 11, theabsorbent core 14 is formed in an hourglass shape.

In the absorbent article 11, it is preferred that side sheets 15extending in the longitudinal direction y are disposed on both sides ofthe top sheet 12 in the width direction x. The side sheet 15 is providedwith a rising elastic member 16 at an inner part thereof in the widthdirection x, and the inner part of the side sheet 15 rises towardwearer's skin by contractive force of the rising elastic member 16 inusing the absorbent article 11, thereby, preventing leakage of excrementsuch as urine and the like.

In the absorbent article 11, the nonwoven fabric laminate of the presentinvention can be used for the back sheet 13 as the exterior sheet. Forexample, in the case of using the nonwoven fabric laminate 1 shown inFIG. 1, the nonwoven fabric laminate 1 may be disposed such that thefirst nonwoven fabric layer 2 is located on the outer side of theabsorbent article 11. By applying the nonwoven fabric laminate of thepresent invention to the back sheet 13 as the exterior sheet, handfeeling of the absorbent article 11 is improved and the appearance ofthe absorbent article 11 seen from the back sheet 13 side is enhanced,for example in the case of using the absorbent article 11 to be attachedto an inner side of an underwear (pants). Moreover strength of the backsheet 13 can be ensured. Or, the nonwoven fabric laminate of the presentinvention may be further provided on the outer side of the back sheet 13as the exterior sheet.

An another example of the absorbent article of the present invention isexplained. FIGS. 6 to 8 show an example of the absorbent article that isapplied to a pants-type disposable diaper. FIG. 6 shows a perspectiveview of a pants-type disposable diaper, FIG. 7 shows a plan view of thepants-type disposable diaper shown in FIG. 6 in a developed state wherea front part and a rear part are disjoined, and FIG. 8 shows across-sectional view along a line VIII-VIII of the pants-type disposablediaper shown in FIG. 7.

An absorbent article (a pants-type disposable diaper) 21 comprises apants member 24 having a waist opening 22 and a pair of leg openings 23,and an absorbent body 27 disposed on a skin-facing side of the pantsmember 24. The pants member 24 has a front part P, a rear part Q and acrotch part R positioned therebetween, and formed into a pants shape byjoining the front part P and the rear part Q. In the absorbent article(a pants-type disposable diaper) 21, the front part P and the rear partQ constitute a body circumference part of the diaper, and a part betweenan edge of the waist opening 22 and an edge of the leg opening 23corresponds to the body circumference part of the diaper.

In the absorbent article 21, the nonwoven fabric laminate of the presentinvention can be used for a sheet member located on the outer side ofthe pants member 24. In FIGS. 6 to 8, the nonwoven fabric laminate ofthe present invention is used for an exterior sheet 25 located on theouter side of the pants member 24, and an inner sheet 26 is laminated onthe skin-facing side of the exterior sheet 25. By providing the exteriorsheet 25 located on the outer side of the absorbent article 21, strengthof the pants member 24 can be ensured while improving the hand feelingand appearance of the absorbent article 21.

The absorbent body 27 is disposed on the skin-facing side of the pantsmember 24 at least at the crotch part R, and comprises a top sheet 28, aback sheet 29 and an absorbent core 30 provided therebetween (see FIGS.7 and 8). In the absorbent article 21, the absorbent body 27 and theabsorbent core 30 are formed in a substantially rectangular shape. Theback sheet 29 is folded along an edge of the absorbent core 30 in thewidth direction x and joined to the top sheet 28.

The absorbent body 27 is provided with rising flaps 31 on both sidesthereof in the width direction x (see FIGS. 7 and 8). The rising flap 31enables preventing leakage of excrement such as urine and the like. Therising flap 31 is preferably liquid-impermeable. The rising flap 31 isprovided with a rising elastic member 32 at an upper end part thereof inits standing state (an end part of a wearer's side), and the rising flap31 is promoted to stand by contractive force of the rising elasticmember 32.

A plurality of waist elastic members 33 are disposed along an edge ofthe waist opening 22 at an end part, with respect to the longitudinaldirection y, of the pants member 24. A waist-gather around a wearer'swaist is formed by the waist elastic member 33, thereby preventingexcrement such as urine and the like from leaking from a back side or anabdomen side.

A plurality of body elastic members 34 extending in the width directionx are disposed at the front part P and the rear part Q of the pantsmember 24. The body elastic members 34 are arranged at wider intervalsthan the waist elastic member 33. The body elastic member 34 functionsto improve fittability around a wearer's body.

Leg elastic members 35, 36 are disposed in the pants member 24 along anedge of the leg opening 23. The leg elastic member consists of a frontleg elastic member 35 disposed along a front side of the edge of the legopening 23 and a rear leg elastic member 36 disposed along a rear sideof the edge of the leg opening 23; and by the front leg elastic member35 and the rear leg elastic member 36, the leg elastic member isdisposed along almost the entire circumference of the edge of the legopening 23. Leg-gathers around wearer's legs formed by the leg elasticmembers 35, 36 prevents excrement such as urine and the like fromleaking from a crotch.

The waist elastic member 33, the body elastic member 34 and the legelastic members 35, 36 may be disposed between the exterior sheet 25 andthe inner sheet 26. Each of the elastic member is preferably bonded tothe exterior sheet 25 and/or the inner sheet 26 in the stretched state.The exterior sheet 25 may be folded back at the edge of the waistopening 22 of the pants member 24 toward the inner sheet 26, and thewaist elastic member 33 may be interposed between the folded andunfolded parts of the exterior sheet 25 and bonded to the exterior sheet25.

In the case that an elastic member extending in the width direction x,such as the waist elastic member 33 and the body elastic member 34, isdisposed between the exterior sheet 25 and the inner sheet 26, the firstjoining part provided in the exterior sheet 25 is preferably formed soas to have a shape that is longer in the longitudinal direction y thanin the width direction x at the body circumference part of the diaper(that is, the front part P and/or the rear part Q). When the firstjoining part is provided in this manner, many wrinkles extending in thelongitudinal direction y are formed in the exterior sheet 25, and thewaist elastic member 33 or the body elastic member 34 can be made hardlyto be seen from the outside of the exterior sheet 25. Specifically, inthe exterior sheet 25, two kinds of joining parts, the first joiningpart and the second joining part, are formed, and therefore, a largenumber of fine wrinkles can be formed in the exterior sheet 25, therebyincreasing the visual shielding effect of the exterior sheet 25.

It is also preferable that a plurality of the first joining parts arealigned in the width direction x and the longitudinal direction y in thebody circumference part of the diaper, and a distance between the firstjoining parts in the width direction x is wider than that in thelongitudinal direction y. Also by providing the first joining part inthis manner, many wrinkles extending in the longitudinal direction y areformed in the exterior sheet 25 when the waist elastic member 33 or thebody elastic member 34 contracts in the width direction x, and as aresult, the waist elastic member 33 or the waist elastic member 34 canbe made hardly to be seen from the outside of the exterior sheet 25.

Materials of members constituting the absorbent article of the presentinvention are explained. The top sheet is a sheet which is located on awearer's side in wearing the absorbent article and preferablyliquid-permeable. Examples of the top sheet include, for example, anonwoven fabric formed from hydrophilic fibers such as cellulose, rayonand cotton; and a nonwoven fabric which is formed from hydrophobicfibers such as polyolefin (e.g., polypropylene, polyethylene), polyester(e.g., PET) and polyamide (e.g., nylon), and in which the hydrophobicfibers are hydrophilized with a surfactant on the surface thereof. Asthe top sheet, a woven fabric, a knitted fabric, a plastic film havingpores may be also used.

The back sheet is a sheet which is located on an opposite side of thewearer, that is an exterior side, in wearing the absorbent article andpreferably liquid-impermeable. Examples of the back sheet include, forexample, a nonwoven fabric formed from hydrophobic fibers such aspolyolefin (e.g., polypropylene, polyethylene), polyester (e.g., PET)and polyamide (e.g., nylon), and a plastic film. As the back sheet, alaminate of a nonwoven fabric and a plastic film may be also used. Inthe present invention, the meaning of “liquid-impermeable” includeswater-repellent.

The pants member (the inner sheet and the exterior sheet) may beliquid-permeable or liquid-impermeable, and a sheet material usable forthe top sheet or the back sheet can be used.

In the case of using a nonwoven fabric for the above sheet material, aspunbonded nonwoven fabric, an air-through nonwoven fabric, apoint-bonded nonwoven fabric, a meltblown nonwoven fabric, an air-laidnonwoven fabric, an SMS nonwoven fabric or the like is preferably usedas the nonwoven fabric. In the exterior sheet (the nonwoven fabriclaminate), since the respective the nonwoven fabric layers are joined toeach other by heat-embossing, they preferably contain thermal fusionfibers such as polyolefin (e.g., polypropylene, polyethylene), polyester(e.g., PET) and polyamide (e.g., nylon).

The absorbent core is not particularly restricted as long as it absorbsexcrement such as urine and the like. As the absorbent core, a clump ofan absorbent material, which is formed into a predefined shape, may beused. The absorbent core may be wrapped with a sheet member such aspaper (e.g., a tissue paper and a thin paper) and a liquid-permeablenonwoven fabric. Examples of the absorbent material contained in theabsorbent core include, for example, a hydrophilic fiber such as acellulose fiber (e.g., a crushed pulp fiber) and an absorbent polymersuch as polyacrylic absorbent polymer, polyasparaginic absorbentpolymer, cellulosic absorbent polymer, and stark-acrylonitrile absorbentpolymer. The absorbent material may contain a thermal fusion fiber. Thethermal fusion fiber may be hydrophilized with a surfactant or the liketo increase affinity with a bodily fluid such as urine.

The absorbent material preferably contains a hydrophilic fiber in viewof increasing absorption speed of urine or the like. In addition, inview of enhancing absorption capacity, the absorbent material preferablycontains an absorbent polymer. Therefore, the absorbent core preferablycontains both a hydrophilic fiber (especially a pulp fiber) and anabsorbent polymer. In this case, the absorbent material is preferablyobtained by mixing an absorbent polymer with a hydrophilic fiberassembly, or dispersing an absorbent polymer on a hydrophilic fiberassembly, for example.

The absorbent core may be a sheet-shaped absorbent body. Examples of thesheet-shaped absorbent body include an object which is formed to containan absorbent polymer but not contain a pulp fiber between nonwovenfabrics. The sheet-shaped absorbent body formed in this manner enableshigh absorption capacity since it contains an absorbent polymer betweennonwoven fabrics. In addition, since the sheet-shaped absorbent bodydoes not contain a pulp fiber between nonwoven fabrics, it can be formedthin without being bulky.

As the sheet-shaped absorbent body, an absorbent fiber may be used forthe absorbent material. Also in this case, the sheet-shaped absorbentbody is formed thin without being bulky. Examples of the absorbent fiberinclude a fiber having a protonated carboxyl group or a carboxylategroup. The absorbent fiber can be obtained by, for example, hydrolyzingan acrylic fiber, thereby converting a nitrile group contained in theacrylic fiber to a carboxylic group, as disclosed in Japanese ExaminedPatent Application Publication No. S52-42916. The carboxyl groupcontained in the absorbent fiber is preferably forms an alkaline metalsalt or an ammonium salt. The absorbent fiber also can be prepared byimmersing a hydrophilic fiber in acrylic acid to deposit acrylic acid onthe surface of the fiber.

This application claims priority to Japanese Patent Application No.2013-203773, filed on Sep. 30, 2013, the entire contents of which areincorporated by reference herein.

REFERENCE SIGNS LIST

-   1: a nonwoven fabric laminate-   2, 49: a first nonwoven fabric layer-   3, 45: a second nonwoven fabric layer-   4, 43: a third nonwoven fabric layer-   5: a fourth nonwoven fabric layer-   6: a first joining part-   7: a second joining part-   11, 21: an absorbent article-   12, 28: a top sheet-   13, 29: a back sheet-   14, 30: an absorbent core-   24: a pants member-   25: an exterior sheet-   26: an inner sheet-   33: a waist elastic member-   34: a body elastic member-   46, 50: a heat-embossing roll-   47, 51: a flat roll-   52: a nonwoven fabric laminate (a continuous body)

1-15. (canceled)
 16. An absorbent article comprising an exterior sheetformed of a plurality of nonwoven fabric layers, wherein the exteriorsheet is located on an outer side of the absorbent article and has afirst nonwoven fabric layer, a second nonwoven fabric layer and a thirdnonwoven fabric layer from the outer side of the absorbent article, thefirst nonwoven fabric layer, the second nonwoven fabric layer and thethird nonwoven fabric layer are joined to each other at a first joiningpart by heat-embossing, the second nonwoven fabric layer and the thirdnonwoven fabric layer are further joined to each other at a secondjoining part by heat-embossing, and an area of the one first joiningpart is larger than that of the one second joining part.
 17. Theabsorbent article according to claim 16, wherein each of the firstnonwoven fabric layer, the second nonwoven fabric layer and the thirdnonwoven fabric layer is made of a spunbonded nonwoven fabric or anair-through nonwoven fabric.
 18. The absorbent article according toclaim 17, wherein the first joining part has a shape that is shorter inan orientation direction of fibers constituting the nonwoven fabric thanin an orthogonal direction thereof.
 19. The absorbent article accordingto claim 16, wherein an elastic member is disposed to a skin-facing sideof the exterior sheet, and the first joining part has a shape that isshorter in an extending direction of the elastic member than in anorthogonal direction thereof.
 20. The absorbent article according toclaim 16, wherein an elastic member is disposed to a skin-facing side ofthe exterior sheet, and a plurality of the first joining parts arealigned in an extending direction of the elastic member and anorthogonal direction thereof, and a distance between the first joiningparts in the extending direction is wider than that in the orthogonaldirection.
 21. The absorbent article according to claim 16, wherein theabsorbent article is a pants-type disposable diaper, an elastic memberextending in a width direction of the diaper is disposed at a bodycircumference part of the diaper between the exterior sheet and an innersheet provided on a skin-facing side of the exterior sheet, and thefirst joining part has a shape that is longer in a longitudinaldirection of the diaper than in the width direction of the diaper. 22.The absorbent article according to claim 16, wherein the absorbentarticle is a pants-type disposable diaper, an elastic member extendingin a width direction of the diaper is disposed at a body circumferencepart of the diaper between the exterior sheet and an inner sheetprovided on a skin-facing side of the exterior sheet, and a plurality ofthe first joining parts are aligned in a longitudinal direction of thediaper and the width direction of the diaper, and a distance between thefirst joining parts in the width direction of the diaper is wider thanthat in the longitudinal direction of the diaper.
 23. A nonwoven fabriclaminate in which a first nonwoven fabric layer, a second nonwovenfabric layer and a third nonwoven fabric layer are laminated in thisorder, wherein the first nonwoven fabric layer, the second nonwovenfabric layer and the third nonwoven fabric layer are joined to eachother at a first joining part by heat-embossing, the second nonwovenfabric layer and the third nonwoven fabric layer are further joined toeach other at a second joining part by heat-embossing, and an area ofthe one first joining part is larger than that of the one second joiningpart.
 24. The nonwoven fabric laminate according to claim 23, whereineach of the first nonwoven fabric layer, the second nonwoven fabriclayer and the third nonwoven fabric layer is made of a spunbondednonwoven fabric or an air-through nonwoven fabric.
 25. The nonwovenfabric laminate according to claim 24, wherein the first joining parthas a shape that is shorter in an orientation direction of fibersconstituting the nonwoven fabric than in an orthogonal directionthereof.
 26. A process for producing a nonwoven fabric laminate,comprising the steps in the sequence set forth: forming a third nonwovenfabric layer; forming a second nonwoven fabric layer on the thirdnonwoven fabric layer; heat-embossing the second nonwoven fabric layerand the third nonwoven fabric layer to join to each other at a secondjoining part; forming a first nonwoven fabric layer on the secondnonwoven fabric layer; and heat-embossing the first nonwoven fabriclayer, the second nonwoven fabric layer and the third nonwoven fabriclayer to join to each other at a first joining part, wherein an area ofthe one first joining part is larger than that of the one second joiningpart.